Modular building unit and methods of forming same

ABSTRACT

The disclosure relates to a building formed of a plurality of modular units, a modular unit, and methods of constructing said module. Each building module comprises two portions, a first inner portion, which coacts with identical first portions of a plurality of other modules to form a common open area for said building, and a second portion which comprises a wing of the finally assembled building. Two methods of forming the modules are disclosed. Each module is a molded construction with an inner and outer shell and a foamed insulating material therebetween. In one method the insulating material is foamed in place. In the second method, a mat of fiberglass and foam blocks is formed wherein the fiberglass matting forms a truss for the wall structure.

Watkins et al.

Aug. 5, 1975 [54] :32:33: ggtg gfigggfiz FOREIGN PATENTS OR APPLICATIONS 898,242 6/1962 United Kingdom 264/45 [76] Inventors: Berne A. Watkins, One Normanskill Delmar 12054; James Primary ExaminerEdward G. Whitby NE 17 Ave-1 Fort Attorney, Agent, or Firm-Pollock, Philpitt & Vande Lauderdale, Fla. 33304 Sande [22] Filed: Jan. 21, 1974 211 App]. No.: 435,064 [57] ABSTRACT The disclosure relates to a building formed of a plural- Related Apphcauo Data ity of modular units, a modular unit, and methods of l l Division Of 20, 1971, constructing said module. Each building module comabandonedprises two portions, a first inner portion, which coacts with identical first portions of a plurality of other [52] US. Cl. 156/93; 52/309; 52/576; modules to f a common open area f Said 1 161/161; 264/45; 1 ing, and a second portion which comprises a wing of [51] Int. Cl. B32b 7/08 the finally assembled building Two methods f f [58] F1eld of Search 52/309, 576, 577; 264/45; ing the modules are disclosed. Each module i a 156/93, 77, 161/161 molded construction with an inner and outer shell and a foamed insulating material therebetween. In one References Cited method the insulating material is foamed in place. In UNITED STATES PATENTS the second method, a mat of fiberglass and foam 3,315,424 4/1967 Smith 52/206 blocks is formed wherein the fiberglass matting forms 3.331.173 7/1967 Eisner 52/309 a truss f r h ll ructure. 3.339.326 9/1967 Derr ct al. l6l/l6l X 3.544417 12/1970 Corzine 156/93 x 1 20 D'awmg F'gures H 'r 4 I :f- 11 I t. 7,1 g

PATENTEDAUB 5M5 3,898,115

SHEET 1 INVENTORS Berne A. Watkins James W. Sedore ATTORNEY SHE-ET PATENTEU AUG 51975 FIG. 6A.

FIG. 7A.

FIG. 6..

PATENTEUAUB 5W5 SHEET FIG. 9

FIG.

m mm V M N id 1 08 W5 w a mm ea BJ ATTORNEY PATENTEUAUB 1 1 3,898,115

SHEET 4 IN VENTORS Berne .A. Watkins James W. Sedore BY wvmw ATTORNEY MODULAR BUILDING UNIT AND METHODS OF FORMING SAME CROSS-REFERENCE TO RELATED APPLICATIONS This is a division of application Ser. No. 209,767, filed Dec. 20, 1971 now abandoned.

This application relates to improvements on US. application Ser. No. 96,090, entitled MODULAR BUILDING UNIT AND BUILDING FORMED THEREFROM, filed on Dec. 8, 1970, and assigned to the assignee of this application.

This application also relates to improvements on US application Ser. No. 182,335, entitled MODULAR UNIT AND BUILDINGS FORMED THEREFROM, filed on Sept. 17, I971 and assigned to the assignee of this application.

BACKGROUND OF THE INVENTION Housing is one of mans basic needs. Modern technology has come to the realization that in order to provide low cost and adequate housing for the members of its society, it must employ modular techniques in the construction of homes and dwellings. The prior art has recognized modular construction as one of the primary areas in which cost reduction for housing is possible. These individual modules are later assembled at the job site. Modular housing has to date been thwarted by a combination of factors including provincial and restrictive building codes and local union disputes over work rules and on-site construction. Although mass production techniques have proved a boon in a variety of fields, todays modern residential dwelling is essentially a hand-crafted product. Inasmuch as the manufacturing process is carried out at the building site, inclement weather can and usually does limit the quantity of buildings completed.

Modular housing, as practiced by the prior art, has overcome a number of these drawbacks. In the first place, the modules can be built at a central location or factory which can be protected from the weather. In addition, mass production techniques can be used and the amount of labor saving equipment which can be used is no longer limited. Once the modules are completed at the factory, they are shipped to the building site and only a minimum amount of skilled labor and equipment is required to assemble the modules into a completed building. However, in order to gain the advantages derived from modular construction, methods must be used which introduce certain disadvantages and drawbacks. Since the technology of modular construction requires a majority of manufacturing operations to take place at the central location of the factory, the modules may become large, heavy and difficult to ship. Furthermore, inasmuch as at least a portion ofthe shipping will be by highway, the width restrictions imposed by state law restrict the size of the modules which can be used.

In constructing modules, it is recognized that one of the lightest, strongest, and most durable of construction materials is a fiberglass reinforced synthetic resin. The use of this material, however, has introduced new problems involved with the anchoring of such modules to the foundation members, and the construction of wall members which will be light, strong, thermal insulating and still inexpensive. Further problems are presented when compound shapes are molded, and it is desired to insert the thermal insulating material between the compound mold elements.

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a low cost housing unit which maximizes the advantages to be gained by modular construction by providing a building which can be made of substantially identical modules. It is another object of the present invention to provide such a housing unit which minimizes the amount of labor and equipment required to assemble a plurality of modules into a building.

It is another object of the present invention to provide a low cost modular building in which the cost of shipping the completed modules to the building site is minimized by providing light weight nestable modules. A further object of the present invention is to provide nestable modules which are extremely light in weight and thereby further reduce the shipping cost while maintaining the structural strength.

It is another object of this invention to provide a method of forming a modular unit wherein the insulating material is foamed in place between two shells of fiberglass reinforced synthetic resin. It is another object of this invention to provide a method of constructing a module wherein the modular wall is inclosed by inner and outer fiberglass reinforced synthetic resin shells. The inner insulating portion of the wall is then formed of a mat of foam blocks and fiberglass matting to provide a light weight inexpensive truss arrangement to substantially strengthen the wall of the modular unit.

DETAILED DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevation of a complete building constructed of a plurality of modular units.

FIG. 2 is a plan view of a complex building constructed with a plurality of modular units.

FIG. 3 is a plan view of a simple structure constructed with a plurality of modular units.

FIG. 4 is an elevation view from the side of one of the modular units.

FIG. 5 is a plan view of one of the modular units.

FIG. 6 is an isometric view of the standard modular unit.

FIG. 6a is an end view of the standard modular unit.

FIG. 7 is an isometric view of an alternate embodiment of the modular unit.

FIG. 7a is an end view of the alternate embodiment of the modular unit.

FIG. 8 is an isometric view of the mold and molding process for preparing the outer shell of a module constructed in accordance with the invention.

FIG. 9 is an isometric view of the mold used in the formation of the inner shell of the invention.

FIG. 10 is an end view of the inner and outer molds when the insulating material is being foamed into place.

FIG. 11 is an elevation view of a plurality of modules stacked for shipping.

FIG. 12 is an isometric view of the inner and outer shells, and the inner and outer mold walls with a rib spaced installed in place.

FIG. 13 is a cross sectional view of the jointused to join together two of the coacting flanges found on the modules.

FIG. 14 is a plan view of one of the coacting edges.

FIG. I5 is an isometric view of a partially completed mat of fiberglass and foam blocks.

FIG. 16 is a cross sectional view of the wall structure wherein foam blocks and fiberglass matting are formed into a truss arrangement.

FIG. 17 is a cross sectional view of the foundation and anchoring means for securing the module to the foundation.

FIG. 18 is a cross sectional view of the flange used to secure the modular wall to the foundation.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention achieves the objects heretofore noted by providing a low cost, easily transported module, which can be substantially and completely fab ricated at a central location or factory using semiskilled labor and mass production techniques. The factory produces complete modules, as shown in FIGS. 4 through 7. Each module is a molded construction comprising an inner and outer shell which are substantially similar in shape. The space intermediate the inner and outer shells is filled with a polyurethane foam, or mat of foam blocks and fiberglass to provide insulation and increased strength. In addition, this space can be used for electrical conduits and heating and cooling ducts if desired. The modules are so molded that once complete, they are nestable or stackable for ease in transportation. This is effected by the shape of the module which decreases in width and height along its longitudinal axis. I

In order to form or assemble a plurality of modules into a building unit, it is first necessary to provide a base which generally comprises a concrete slab. In this base, provision is made for water and sewer piping and gas piping if desired. Once the slab is ready, it is only necessary to position the modules on the slab as illustrated in FIG. 1. The forward portion of each module coacts with the forward portion of a plurality of other modules to form an enclosed open area for the building. In order to effect this mating of modules, the included angle of the forward portion of the module equals 360 divided by the number of modules it is desired to use in forming a complete building. For example, the building of FIG. 1, 2 and 3 each use six modules and the included angle in the forward portion of each of the modules is 60.

Although in the embodiment shown, six modules are employed to form a building of distinctive shape, it will be at once apparent to those skilled in the art that more or less modules can be used to form a building of similar shape by varying the included angle in the forward portion of the modules. Each of the modules shown in FIG. 1 is of identical shape and the only other building elements required to complete the building are the end wall portions 11 which enclose the wings of the building. The six wing building shown in FIG. 1 is a three bedroom home with living room, dining room, kitchen and bathroom. These various rooms are provided as follows. The central open area forms a living room which is approximately circular and feet in diameter, while three module wings form three bedrooms. A wing is used for a dining room, and another forms a kitchen and bathroom wing. The last module is used for an entry way.

It is possible to vary the number of modules which form a complete building, and it is also possible to form even larger buildings by connecting a number of basic buildings together to form repeating sequences as illustrated in FIG. 2. FIG. 2 shows how two basic six module buildings 12 and 13 can be connected together by connecting the rear portions of two modules. Of course, this basic sequence can be expanded to any number of such buildings. As has been explained above, the use of six modules to form a building is merely vexplanary as any number of modules can be assembled with their forwardmost portions coacting to form a central open area according to the principles of the present invention. In particular, any number of modules from three on up can be used.

Additionally, if desired, the length of each module may be varied from a minimum at which the module consists entirely of the forward portion as illustrated by the module 14 in FIG. 3. Modules with wing portions of intermediate lengths such as those illustrated at 15 in FIG. 3 may also be used.

It is also possible tovary the width of the wing por tion of the module as illustrated by the module 16 in FIG. 2. The construction of this alternate embodiment of the invention will be discussed later. It can be used, however as a reduced width module for bathrooms, storage areas, entry ways and the like wherein the full width of the wing portion is not needed.

A practical limit is placed on the number of modules which can coact together to form a central open area. The radius of the central area formed by the coaction of the forward portions of the modules is related to the width of the modules and the number of modules which are used to form such a central open area for modules. As the number of modules increases, the forward portion of the module correspondingly increases with diminishing contribution to the total area of the building.

The configuration of the module itself is illustrated in FIGS. 4 through 7L For discussion purposes, the module can be broken up into a forward portion 17 which coacts with identical forward portions of a plurality of other modules to form a central open area in a building, and a rearward portion 18 which will form one of the wings of the building. The rearward portion of the module is an inverted generally U-shaped member which projects outwardly from the open space. The length of each individual module may also be varied by varying the length of the wing portion 18. The area encompassed by the building will vary directly with the length of the modules employed to form the building. As pointed out previously, it is also possible to use modules of varying length in the assembly of a single building so long as the forward or innermost portions 17 of the module which coact together to form a central open area, are equal in width. Thus the innermost portion alone as illustrated in FIG. 4 by the dotted line 19-19 can be used as the module 14 illustrated in FIG. 3. An intermediate length module such as module 15 as illustrated in FIG. 3 may be formed by terminating the wing portion of the dotted line indicated by 20-20. The short modules may be desired for an entry way or the like, while a longer module may be used for enlarging the size of a master bedroom, a recreation room, or a garage. As illustrated in FIG. 6 and 7, the modules of this invention are shown in a generally rectangular or angular shape. The modules of the copending application were illustrated as smooth flowing, contoured arches. This type of module is illustrated in the copending application Ser. No. 96,090, entitled Modular Unit and Building Formed Therefrom, filed Dec. 8, I970,

now abandoned and is assigned to the assignee of this application.

While these modules possess esthetic beauty, and while the arch form and gently contoured surfaces increase the structural strength of the module, it has been found desirable in certain applications to provide for the full ceiling height over the entire width of the module. This type of module is illustrated in FIGS. 4 through 7. New methods of construction and methods of reinforcing the module have made it possible to provide structural strength necessary to form this type of module from the light weight, low cost synthetic resin shells previously discussed in the copending application.

As can best be seen in FIGS. 4 and 5, the forward portion of each module defines a pair of coacting edges 21 and 22 which are adapted to coact with other modules to form a completed building. These coacting edges 21 and 22 are planar and the two planes intersect at the apex of the triangular portion of 17 indicated by the numeral 23. Each of these coacting edges define an opening generally indicated by the numeral 24 in FIG. 4 in the side wall of the module which cooperates with other such openings to define and form the open space of the completed building.

In the specific embodiments illustrated in FIGS. 4 through 7, the width of the module at the forward edge of the rearward wing indicated by numerals 25-25 in FIG. 5 may be l2 feet even. At the terminal portion of the module where the rearward panel is installed, indicated by the numerals 2626, the module may be I 1 feet in width. The overall length of the module from line 2626 to the apex 23 may be 28 feet. As illustrated in FIG. 4, the height of the module also gradually decreases along its longitudinal axis from the highest point in the forward portion of the module to the lowest point in the rearwardmost portion of the module. This decreasing of the height and width can be seen in FIGS. 4 and 5, and it is this characteristic of the module which allows one module to be nested or stacked on other modules thus decreasing the space required for transporting the modules, and correspondingly reducing the cost of transportation. The modules are stacked one upon another with the longitudinal overlap of approximately 1 foot as illustrated in FIG. 11.

Preferably the units are shipped to the job sites stacked in groups or units for the completed building. Depending on the number of units shipped, and the size and complexity of the building, the prefabrication may also include the rear wall and any attendant windows or doors installed therein. Alternately, the module and its rear wall may be shipped separately to the building site and united at the time a plurality of modules are united.

As was previously pointed out, FIG. 6 is an isometric view of a conventional module constructed in accordance with my invention. FIG. 6a is an end view of the same module viewed from the rearward portion or wing portion of the module. FIG. 7 is an alternate embodiment of the module that is used whenever a smaller or narrower module is desired. The inner or forward portion 17 of the module is constructed of the same size angle. and with the same distance parameters as are all the other modules. This is to ensure that when this module is combined with other modules, it will complete its segment of the construction providing the onclosed open space. The wing portion, however, has

been narrowed by the indents 27 and 28. These indents make it possible to provide a room with smaller or narrower cross sections on the exterior of a larger modular building. This type of narrowed module would find particular application to entry ways, kitchens, pantries, bathrooms and the like. It should be pointed out that any sized blank panel 27 and 28 could be provided to vary the width of the wing portion of the module. It would also be possible to provide all of the spacer panel such as 28 on one side of the module thereby providing an asymmetric module. The module illustrated in FIG. 7 and 7a is shown in FIG. 2 as module 16. Module 16 has been reduced both in width and in length to provide an entryway for the building disclosed in FIG. 2.

As has been discussed previously, each module is formed of an inner shell and an outer shell preferably of molded polyester resin which is formed or molded into special forms. FIGS. 8 and 9 illustrate the female and male forms necessary to form the inner and outer shells of the module.

FIG. 8 illustrates the use of the female mold to form the outer shell of the module. The mold itself 29 is physically supported by beams and girders generally illustrated at 30. In forming the outer shell, a gel coat is first sprayed on the interior of mold 29. Since mold 29 has a smooth and finished surface, this renders the exterior of the shell smooth and finished in the same manner. After the gel coat or finish coat has been applied over the entire surface of mold 29 the substantive resin layer is applied. This layer is a mixuture of chopped fiberglass fibers and polyester or epoxy resin which is sprayed onto the interior of mold 29. This layer is sprayed on to a thickness of approximately one sixteenth of an inch. Alternately, of course, it would be possible to lay up this substantive layer by applying woven strips of fiberglass along with brushed or sprayed resin.

FIG. 8 illustrates the manner in which the interior of the module is formed. The workmen work from a movable scaffold 31 which is suspended from girder 32 by means of adjustable hangers 33 and 34. This enables the workman to reach the entire interior surface of the mold from his scaffolding without disturbing the freshly sprayed resin layer. After the molding operation is completed, the girders 35 and 36 are removed, together with the scaffolding arrangement for the formation of the module.

Concurrently with the spraying or laying up of the exterior skin for the module, the interior skin or shell is formed on a male mold illustrated in FIG. 9. This mold follows the same contour as does the mold illustrated in FIG. 8, and this results in a male and female shell or inner and outer shell whose walls are substantially parallel throughout the modular surface. The male mold 37 is supported by means of girders 38 and interior supports 39. I

For the purposes of clarity, diagrammatic representations as to the form of the interior supports and girders have been used in both FIG. 8 and FIG. 9. The interior shell is formed by spraying a gel coat on the exterior of mold 37 in a manner similar to the formation of the exterior shell described with reference to FIG. 8. After the gel coat has been sprayed, the structural layer is formed either by spraying the exterior of mold 37 with a combination of chopped fiberglass fibers and polyester resin, or by laying up" the shell with layers of fiberglass and individual coats of resin. The final thickness of the interior shell is approximately one sixteenth of an inch.

After the inner and outer shells have been formed on molds 37 and 29, the interior mold is inverted and placed on the structural supports surrounding mold 29 in a manner illustrated in FIG. 10. The main cross beams 38 that support mold 37 are now resting on the main structural support members 30 provided for mold 29. This suspends the inner shell above and apart from the outer shell. The molds are separated by a distance of approximately 2 inches throughout the entire area of the modular unit. The insulating material is then foamed into place and delivered to the interior space between the shells by means of nozzle 40. A selffoaming polyurethane material is used, and it is injected between the molds in liquid form to insure that the insulation reaches every part of the cavity between the two shells. The rough inside texture of the exterior shell caused by the sprayed fibers, and the rough exterior portion of the interior shell caused by the sprayed fibers combine with the self-foaming polyurethane foam to create a rigid and bonded composite layer. These irregularities combine to provide a bonding without the use of any glue, and the laminate strength of the two shells is vastly increased. For example, a large single panel of fiberglass reinforced synthetic resin has a high tensile strength, but is quite flexible. By combining two skins together with a solid inner connecting core, the forces on one side of the panel which would cause deflection ofa single skin are converted to tensile stress on the opposite side of the core. The effect is synergistie and the combined panel achieves greater rigidity than the combined rigidity of all the components. The sandwich construction results in a panel which has a flexural modulus value of 850,000 on test standard D- 790-59T, a compression value of 16,000 on a test standard D-695-54, and a tensile strength value of 9000 as measured by test method D-882-56-T. This novel wall construction would find application not only in the formation of modular units, but wherever light weight, high strength synthetic panels or structural materials are needed.

As a practical matter, it has been found convenient to insert internal ribs or spacer blocks between the shells before the foamed insulation is poured. Referring to FIG. 12, the interior mold 37 has formed thereon interior shell 41. Mold 29 has formed on its interior surface the exterior shell 42. A spacer block 43 has been inserted between the two shells. Preferably this block is inserted by fastening it to the exterior of the shell 41 formed on mold 37 before the mold is inverted and placed into the female mold 29. Alternately, it could be placed on the interior surface of shell 42 formed on the interior of mold 29.

The spacer blocks may be formed from polyurethane, cardboard saturated with polyester resin, or with preformed resin blocks. They not only provide truss reinforcement for the two shells, but they also provide channels which may be left void between the shells in order to conduct electrical Wiring, water pipes or the like. It would even be possible in selected areas to use relatively wide spacing between the blocks and use the passageway as an air conduit for heating and cooling the house.

The use of the liquid self-foaming insulation is particularly desirable in this respect since the entire conduit and duct layout for the module may be made on the skin 41 formed on the exterior of mold 37. It is inevitable in forming those types of passageways that some irregular cavities will result. The use of the liquid selffoaming polyurethane will insure that the irregular cavities are completely filled. The use of foam increases the strength of the module while decreasing the weight because less synthetic resin is required to maintain any given strength factor. The use of foam also stops the spread offire should a fire break out within the module.

An alternate form of wall construction is illustrated in FIGS. 15 and 16. This form of wall construction utilizes a W core between the inner and outer shells. In order to form the W core a mat 50 is first laid on a relatively flat surface. While this mat is preferably woven fiberglass, any suitable synthetic or natural fiber may be used. If a synthetic fiber is used, it must be compatible with the type of resin that will be used later on in the forming process. After the first mat 50 has been positioned, a plurality of foam blocks illustrated by the triangular elongated blocks 51 and 52 are laid side by side to cover the entire surface area of mat 50. A second mat 62 is then laid over the foam blocks and stitched in place to the mat 50 as indicated at 53, 54 and 55. While triangular shaped blocks have been illustrated in the formation of a W core, it is apparent that other blocks of compatible configuration could be provided. After the first stage illustrated in FIG. 15 has been completed, a second layer of triangular blocks is placed on top of the first as illustrated in FIG. 16. These blocks are illustrated at 56, 57 and 58. When triangular blocks are used the apex of the respective triangle fits within the void defined by two of the adjacent blocks previously laid upon mat 50.

Immediately before the second layer of blocks is positioned, the mat 62 is sprayed or impregnated with a polyester or epoxy resin. Immediately thereafter the second layer of blocks 56, 57 and 58 are positioned in place, and a third fiberglass mat 59 is laid over the second layer of blocks. At his point, the mats 50 and 59 are impregnated with resin and the entire panel is positioned in place on the exterior of mold 37. The rather flexible nature of the mats and foam blocks makes it possible to lay large sections of the mat or W core into place even on compound curves. The invention is particularly suited to the relatively square module illustrated in FIGS. 4-7. As was in the case of the foamed in place construction, various channels may be defined between the mat layers on the exterior of mold 37 to define channels for conduits, water pipes, and heating and cooling ducts. After the W" core mat has been positioned on one of the shells, the inner shell is again raised over the outer shell and dropped into place. A fresh layer of resin is sprayed or applied immediately before the joining of the two shells.

One distinct advantage to using the W" core in a module construction is the increase in strength, and reduction in weight. As illustrated in FIG. 16, the W" core construction comprises an inner skin 60 and an outer skin 61 with three layers of woven fiberglass therebetween and a plurality of foam blocks. As illustrated in FIG. 16, the W core provides a truss arrangement between the interior and exterior shells whereby the mat member 62 is alternately secured to the inner and outer shells on each of its undulations. The woven fiberglass when impregnated with resin becomes an extremely strong material, and it is thereby possible to reduce the density of the foam blocks SI,

52. 56. 57 and 58 and thereby provide for a core with the same or greater strength with half the density or weight. For example, a typical module as illustrated in FIGS. 4-7 when constructed with foamed in place polyurethane may weigh between 400 and 800 pounds. When formed as illustrated in FIGS. and 16, it may weigh as little as 200 to 400 pounds. As was pointed out previously, the shape of the foam blocks may be altered as desired in order to form corresponding shapes. A plurality of rectangular blocks could be used in the same manner, as could a plurality of curved blocks which would form a sinusoidal shape for mat 62 in place of the relatively angular W shape.

The light weight of the module while a decided advantage in shipping does cause some additional disadvantages. In a normal house, the foundation or slab of the home provides a weight distributing member for the home to distribute the weight of the house over a suitable area of land. Were it not for the foundation, the house would slowly sink into the ground along its wall surfaces. Quite the converse is true in low weight modular housing. Here the foundation is not provided to provide additional strength for the module, but rather to provide an anchor for the home to literally keep it from being blown away during heavy inclement weather.

One means for keeping the home solidly anchored to the floor slab is illustrated in FIGS. 17 and 18. Referring to FIG. 17, a floor slab 70 is poured in place on the job site. An indent 71 is provided around the periphery of the floor slab and on the interior wherever the module wall will contact the floor slab. Thus the floor slab will define a continuous recess indent 71 which will define the periphery of the modular members for the entire house.

As can be seen in FIG. 18, the wall member 72 is provided with a flange 73 on its lowermost portion. While this flange can be made of two pieces as illustrated in FIG. 18, it can also be made from a single unitary piece by molding, extrusion or the like. Furthermore, while the flange member 73 has been illustrated as synthetic resin in FIG. 18, it is apparent that any metal such as aluminum, steel, or the like would be suitable for the application. The flange has defined therein an opening 74 to accommodate the fastening means which will secure it to the floor slab.

In the preferred embodiment, the floor slab is poured with a plurality of anchor bolts 75 placed in the indents 71 in predetermined spaced locations. These bolts may be placed at regular intervals such at every 2 feet on center. Alternately, in areas of heavy stress loading, the bolts may be congregated to provide a suitable distribution of the stress along the wall member. After the wall member 72 has been positioned in place as illustrated in FIG. 17, a second peripheral slab member 76 is poured to completely fill the recessed depression 71 and bring it flush with the surface of floor 70. In doing so, the bracket means 73 attached to wall member 72 and the anchoring means 75 are completely covered by the peripheral slab 76. Thus a strong and permanent seal is formed between the wall member 72 and the floor slab 70 that will completely prevent the entry of any moisture, air or the like, but which will adequately provide for the anchoring of the module to the floor slab.

The flange member 73 may be attached to the wall member 72 in a variety of ways. An indent may be defined on the interior and exterior shells along the periphery of the module as illustrated in FIG. 18. The flange may then be attached to the wall by means of polyester resin or other suitable adhesives. Alternatively, through bolts could be utilized which would bolt the flange to the respective inner and outer shells of wall member 72. Additionally, through bolts could be extended outwardly beyond the flange 73. These extended portions would then become embedded in the peripheral slab 76 and would aid the anchor means in anchoring the wall to the floor slab 70.

As was pointed out previously, the modules are joined together along their coacting edges to form a common unitary structure. The individual coacting edges of the modules are joined together as illustrated in FIGS. 13 and 14. The flanges 86 are joined together along their length by a plurality of bolts, rivets or other fastening means illustrated by bolt 87. The mating joint on the interior of the module is covered by decorative strip 88. Onthe exterior of the module the bolts and flanges are protected by slip-on plastic clamp cover 89 which extends the length of the coacting joint. The hollow space 90 defined on either side of the flanges 86 provides a rain and snow leader to drain water from the roof of the building and prevent the seepage of water through the opening provided through the fastening means 87. The clamp and sealing means 89 also prevent the entry of water or other moisture through the coacting joint. The individual flange or coacting edge is specifically illustrated in FIG. 14. The inner and outer wall portions 83 and 84 are normally spaced from one another with the insulating layer 85 filling the void therebetween. The inner and outer members come together at the flange surface wherein the outer wall portions define a generally U-shaped channel portion which jndents into the spaced apart portion 85. The inner wall portion 83 extends out beyond the U-shaped portion and then converges with the outer wall to form the flange 86.

While specific means have been illustrated and specific examples and mentions given herein, it is to be understood that various modifications of the module and the cooperation between respective modules would occur to one skilled in the art. Accordingly, it is to be understood that the present invention is not limited to these illustrations and examples, but is to be limited only in accordance with the appended claims.

We claim:

1. A method of constructing a modular unit capable of forming a complete building when joined with a plurality of other units comprising the steps of:

a. forming an inner shell for said modular unit on a male mold,

b. forming an outer shell for said modular unit within a female mold cavity,

c. forming a flexible mat of woven fiberglass and foam blocks by l. assembling a plurality of elongated triangular blocks together along their longitudinal edges, said blocks being assembled above a first mat of woven fiberglass,

2. overlaying said blocks with a second mat of woven fiberglass and stitching the first and second layers together between said blocks,

3. assembling a second layer of triangular blocks above said first layer with each block of said second layer being disposed between a pair of adja- 1 1 12 cent blocks of said first layer so as to form a flat said flexible mat and to said shells while laying up uniform upper surface, said mat upon one of said shells. 4. overlaying said second layer of blocks with a e. clamping said shells together while still in the mold third mat of woven fiberglass and securing said cavity to form a modular unit with inner and outer third mat to said second layer of blocks, shells and foam core.

d. applying a resin coating to the outer surfaces of 

1. A METHOD OF CONSTRUCTING A MODULAR UNIT CAPABLE OF FORMING A COMPLETE BUILDING WHEN JOINED WITH A PLURALITY OF OTHER UNITS COMPRISING THE STEPS OF: A. FORMING AN INNER SHELL FOR SAID MODULAR UNIT ON A MALE MOLD. B. FORMING AN OUTER SHELL FOR SAID MODULAR UNIT WITHIN A FEMALE MOLD CAVITY. C. FORMING A FLEXIBLE MAT OF WOVEN FIBERGLASS AND FOAM BLOCKS BY
 1. ASSEMBLING A PLURALITY OF ELONGATED TRIANGULAR BLOCKS TOGETHER ALONG THEIR LONGITUDINAL EDGES, SAID BLOCKS BEING ASSEMBLED ABOVE A FIRST MAT OF WOVEN FIBERGLASS
 2. OVERLAYING SAID BLOCKS WITH A SECOND MAT OF WOVEN FIBERGLASS AND STITCHING THE FIRST AND SECOND LAYERS TO GETHER BETWEEN SAID BLOCKS,
 2. overlaying said blocks with a second mat of woven fiberglass and stitching the first and second layers together between said blocks,
 3. assembling a second layer of triangular blocks above said first layer with each block of said second layer being disposed between a pair of adjacent blocks of said first layer so as to form a flat uniform upper surface,
 4. overlaying said second layer of blocks with a third mat of woven fiberglass and securing said third mat to said second layer of blocks, d. applying a resin coating to the outer surfaces of said flexible mat and to said shells while laying up said mat upon one of said shells. e. clamping said shells together while still in the mold cavity to form a modular unit with inner and outer shells and foam core.
 3. ASSEMBLING A SECOND LAYER OF TRIANGULAR BLOCKS ABOVE SAID FIRST LAYER WITH EACH BLOCK OF SAID SECOND LAYER BEING DISPOSED BETWEEN A PAIR OF ADJACENT BLOCKS OF SAID FIRST LAYER SO AS TO FORM A FLAT UNIFORM UPPER SURFACE,
 4. OVERLAYING SAID SECOND LAYER OF BLOCKS WITH A THIRD MAT OF WOVEN FIBERGLASS AND SECURING SAID THIRD MAT TO SAID SECOND LAYER OF BLOCKS, D. APPLYING A RESIN COATING TO THE OUTER SURFACES OF SAID FLEXIBLE MAT AND TO SAID SHELLS WHILE LAYING UP SAID MAT UPON ONE OF SAID SHELLS. E. CLAMPING SAID SHELLS TOGETHER WHILE STILL IN THE MOLD CAVITY TO FORM A MOLDULAR UNIT WITH INNER AND OUTER SHELLS AND FOAM CORE. 